ENGINE ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

CAUTION:

As the engine assembly with transaxle is extremely heavy, the engine lifter may suddenly drop if the instructions listed in the repair manual are not followed. Therefore, always follow the instructions listed in the repair manual when performing this procedure.

PROCEDURE

INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

Tech Tips

Perform this procedure only when replacement of the engine mounting insulator sub-assembly RH is necessary.
1. Install the engine mounting insulator sub-assembly RH with the 3 bolts.
  
  Torque:
  
  95 N*m { 969 kgf*cm, 70 ft.*lbf }
INSTALL ENGINE MOUNTING INSULATOR LH

Tech Tips

Perform this procedure only when replacement of the engine mounting insulator LH is necessary.
1. Install the engine mounting insulator LH with the 4 bolts.
  
  Torque:
  
  95 N*m { 969 kgf*cm, 70 ft.*lbf }
INSTALL REAR ENGINE MOUNTING INSULATOR
Tech Tips

Perform this procedure only when replacement of the rear engine mounting insulator is necessary.
1. Install the rear engine mounting insulator with the 2 bolts and 2 nuts in the order shown in the illustration.
  
  Torque:
  
  95 N*m { 969 kgf*cm, 70 ft.*lbf }
INSTALL ENGINE HANGER

Click here
REMOVE ENGINE FROM ENGINE STAND
Note
- Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.
- With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.
1. Install a sling device and chain block to the engine and hang the engine.
2. Remove the engine from the engine stand.
FIX ENGINE ASSEMBLY

Click here
INSTALL FLYWHEEL WITH DAMPER ASSEMBLY (for Manual Transaxle)
1. Using SST, hold the crankshaft pulley.
  
  SST
  
  09213-58014 ( 91551-80840 )
  
  09330-00021
2. Using a T55 "TORX" socket wrench, install the flywheel with damper assembly with 8 new bolts and uniformly tighten the bolts in several steps in the sequence shown in the illustration.
  
  Torque:
  
  70.6 N*m { 720 kgf*cm, 52 ft.*lbf }
  Note
  
  Do not reuse the flywheel installation bolts.
  
  Be sure to check the tightening torque within 5 minutes after tightening.
  
  Do not impact or damage the flywheel installation bolts. Be sure to handle them carefully.
  
  Make sure there is no oil on the bolts.
  Tech Tips
  
  Make sure that the seating surface of the flywheel installation bolts and installation surfaces of the crankshaft and flywheel with damper assembly are free from oil and foreign matter.

INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transaxle)

Using SST, hold the crankshaft pulley.

SST

09213-58014 ( 91551-80840 )

09330-00021

*1	Drive Plate and Ring Gear Sub-assembly
*2	Rear Drive Plate Spacer
*3	Front Drive Plate Spacer (Reversible)
*a	Engine Side
*b	Transaxle Side

Install the front drive plate spacer, drive plate and ring gear sub-assembly and rear drive plate spacer to the crankshaft.

Tech Tips

The front drive plate spacer is reversible.
As the rear drive plate spacer and drive plate and ring gear sub-assembly are not reversible, be sure to install them so that they are facing in the direction shown in the illustration.

*1 Adhesive

Apply a few drops of adhesive to 2 or 3 threads at the end of each of the 8 bolts.

Adhesive

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
Install and uniformly tighten the 8 bolts in several steps, in the sequence shown in the illustration.

Torque:

92 N*m { 938 kgf*cm, 68 ft.*lbf }

Note

Do not start the engine for at least an hour after installing the drive plate and ring gear sub-assembly.

INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle)

Click here
INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle)

Click here
INSPECT AND ADJUST CLUTCH COVER ASSEMBLY (for Manual Transaxle)

Click here
INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)

Click here
INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle)

Click here
INSTALL STIFFENER PLATE LH
1. Temporarily install the stiffener plate LH with the 4 bolts.
2. While holding the stiffener plate LH against the transaxle assembly, tighten bolt A, and then tighten bolts B, C and D.
  
  Torque:
  
  46 N*m { 469 kgf*cm, 34 ft.*lbf }
INSTALL STIFFENER PLATE RH
1. Temporarily install the stiffener plate RH with the 4 bolts.
2. While holding the stiffener plate RH against the transaxle assembly, tighten bolt A, and then tighten bolts B, C and D.
  
  Torque:
  
  46 N*m { 469 kgf*cm, 34 ft.*lbf }
INSTALL OIL PAN INSULATOR
1. Install the oil pan insulator with the 2 bolts.
  
  Torque:
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf }
INSTALL ENGINE MOUNTING BRACKET LH

Tech Tips

Perform this procedure only when replacement of the engine mounting bracket LH is necessary.
1. Install the engine mounting bracket LH with the 4 bolts.
  
  Torque:
  
  64 N*m { 653 kgf*cm, 47 ft.*lbf }
INSTALL REAR ENGINE MOUNTING BRACKET
1. Temporarily install the rear engine mounting bracket with the 4 bolts.
2. Tighten the 4 bolts of the rear engine mounting bracket in the order shown in the illustration.
  
  Torque:
  
  45 N*m { 459 kgf*cm, 33 ft.*lbf }
INSTALL FRONT ENGINE MOUNTING BRACKET
1. for Manual Transaxle:
  
  Temporarily install the front engine mounting bracket with the 3 bolts.
2. for Manual Transaxle:
  
  Tighten the 3 bolts of the front engine mounting bracket in the order shown in the illustration.
  
  Torque:
  
  64 N*m { 653 kgf*cm, 47 ft.*lbf }
3. for Automatic Transaxle:
  
  Temporarily install the front engine mounting bracket with the 4 bolts.
4. for Automatic Transaxle:
  
  Tighten the 4 bolts of the front engine mounting bracket in the order shown in the illustration.
  
  Torque:
  
  64 N*m { 653 kgf*cm, 47 ft.*lbf }
INSTALL ENGINE WIRE

Click here
INSTALL STARTER ASSEMBLY

Click here
INSTALL NO. 1 AIR TUBE
1. Install the No. 1 air tube with the 2 bolts and tighten the clamp.
  
  Torque:
  
  for bolt
  
  24 N*m { 245 kgf*cm, 18 ft.*lbf }
  
  for clamp
  
  6.5 N*m { 66 kgf*cm, 58 in.*lbf }
  
  Note
  
  Before installation, remove any oil residue from the inside of the No. 1 air tube and air hose.
INSTALL ENGINE WITH TRANSAXLE
1. Temporarily install the front engine mounting insulator with the through bolt and nut.
2. *1 Alignment Mark
  
  *2 Protrusion
  
  Temporarily install the front suspension member with the through bolt.
  
  Tech Tips
  
  When installing the front suspension member, align the protrusion of the engine mounting bracket with the alignment mark of the engine mounting insulator.
3. Set the engine assembly with transaxle on the engine lifter.
  
  Tech Tips
  
  Place the engine on wooden blocks or equivalent so that the engine is level.
4. Operate the engine lifter and lift the engine assembly with transaxle to the position where the engine mounting insulator LH and engine mounting insulator sub-assembly RH can be installed.
  
  CAUTION:
  
  Do not raise the engine more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.
  Note
  - Make sure that the engine is clear of all wiring and hoses.
  - While raising the engine into the vehicle, do not allow it to contact the vehicle.
  - Align the matchmarks on the intermediate shaft and pinion.
5. Temporarily install the 2 bolts to the front suspension member sub-assembly.
6. Temporarily install the front suspension member rear brace RH and front suspension member rear brace LH with the 6 bolts.
7. Connect the engine mounting insulator LH with the bolt and nut.
  
  Torque:
  
  56 N*m { 571 kgf*cm, 41 ft.*lbf }
  
  Tech Tips
  
  While holding the bolt in place, tighten the nut.
8. Connect the engine mounting insulator sub-assembly RH with the 2 bolts and 2 nuts.
  
  Torque:
  
  for bolt and nut A
  
  95 N*m { 969 kgf*cm, 70 ft.*lbf }
  
  for nut B
  
  52 N*m { 530 kgf*cm, 38 ft.*lbf }
9. Tighten the 8 bolts.
  
  Torque:
  
  for bolt A
  
  137 N*m { 1397 kgf*cm, 101 ft.*lbf }
  
  for bolt B
  
  93 N*m { 948 kgf*cm, 69 ft.*lbf }
10. Install the front crossmember sub-assembly with the 6 bolts.
  
  Torque:
  
  for bolt A
  
  99 N*m { 1010 kgf*cm, 73 ft.*lbf }
  
  for bolt B
  
  95 N*m { 969 kgf*cm, 70 ft.*lbf }
11. Remove the 2 bolts, No. 1 engine hanger and No. 2 engine hanger.
12. Tighten the through bolt of the rear engine mounting insulator.
  
  Torque:
  
  95 N*m { 969 kgf*cm, 70 ft.*lbf }
  
  Tech Tips
  
  Check that the protrusion of the engine mounting bracket is aligned with the alignment mark of the engine mounting insulator.
13. Tighten the through bolt and nut of the front engine mounting insulator.
  
  Torque:
  
  145 N*m { 1479 kgf*cm, 107 ft.*lbf }
  
  Note
  
  While holding the nut in place, tighten the through bolt.
INSTALL FUEL HOSE PROTECTOR
1. Install the fuel hose protector to the cylinder head sub-assembly.
  
  Torque:
  
  40 N*m { 408 kgf*cm, 30 ft.*lbf }
INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH
1. Install the front suspension member reinforcement LH with the 4 bolts.
  
  Torque:
  
  99 N*m { 1010 kgf*cm, 73 ft.*lbf }
INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH

Click here
INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT (for Automatic Transaxle)
1. Turn the crankshaft to gain access to the installation locations of the 6 torque converter assembly setting bolts and install each bolt while holding the crankshaft pulley bolt with a wrench.
  
  Torque:
  
  44 N*m { 449 kgf*cm, 32 ft.*lbf }
  
  Note
  
  Install the black bolt first, and then the 5 silver bolts.
2. Install the oil pan insulator and temporarily install the 2 bolts.
  
  Torque:
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf }
INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

Click here
INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

Click here
INSTALL FRONT AXLE ASSEMBLY LH

Click here
INSTALL FRONT AXLE ASSEMBLY RH

Tech Tips

Perform the same procedure as for the LH side.
CONNECT TIE ROD END SUB-ASSEMBLY LH

Click here
CONNECT TIE ROD END SUB-ASSEMBLY RH

Tech Tips

Use the same procedure described for the LH side.
CONNECT FRONT STABILIZER LINK ASSEMBLY LH

Click here
CONNECT FRONT STABILIZER LINK ASSEMBLY RH

Tech Tips

Perform the same procedure as for the LH side.
CONNECT FRONT SPEED SENSOR LH

Click here
CONNECT FRONT SPEED SENSOR RH

Tech Tips

Use the same procedure described for the LH side.
INSTALL FRONT AXLE SHAFT NUT LH

Click here
INSTALL FRONT AXLE SHAFT NUT RH

Tech Tips

Perform the same procedure as for the LH side.
INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

Click here
CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

Click here
INSTALL COLUMN HOLE COVER SILENCER SHEET

Click here
CONNECT CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle)
1. Connect the clutch release cylinder assembly and clutch flexible hose bracket with the 4 bolts.
  
  Torque:
  
  for bolt A
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
  
  for bolt B
  
  19 N*m { 194 kgf*cm, 14 ft.*lbf }
CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)
1. Connect the transmission control cable assembly to the transmission control cable bracket with 2 new clips.
2. Install the 2 pins.
CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle)
1. Connect the transmission control cable assembly with the nut and a new clip.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
CONNECT SUCTION HOSE SUB-ASSEMBLY
1. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the hose joint.
  
  Compressor Oil
  
  ND-OIL 8 or equivalent
2. Install the O-ring to the suction hose sub-assembly.
3. Connect the suction hose sub-assembly to the cooler compressor assembly and install the bolt.
  
  Torque:
  
  9.8 N*m { 100 kgf*cm, 87 in.*lbf }
4. Connect the connector to the cooler compressor assembly.
CONNECT DISCHARGE HOSE SUB-ASSEMBLY
1. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the hose joint.
  
  Compressor Oil
  
  ND-OIL 8 or equivalent
2. Install the O-ring to the discharge hose sub-assembly.
3. Connect the discharge hose sub-assembly to the cooler compressor assembly and install the bolt.
  
  Torque:
  
  9.8 N*m { 100 kgf*cm, 87 in.*lbf }
INSTALL RADIATOR RESERVOIR ASSEMBLY
1. Install the radiator reservoir assembly with the 2 bolts.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
2. Connect the water by-pass hose to the radiator reservoir assembly, and slide the clamp to secure the hose.
CONNECT NO. 2 WATER BY-PASS HOSE
1. Connect the No. 2 water by-pass hose to the No. 4 water by-pass pipe and slide the clamp to secure the hose.
CONNECT NO. 2 RADIATOR HOSE
1. Connect the No. 2 radiator hose to the water inlet housing and slide the clamp to secure the hose.
INSTALL INTERCOOLER AIR HOSE

Click here
CONNECT RADIATOR HOSE SUB-ASSEMBLY
1. Connect the radiator hose sub-assembly to the cylinder head sub-assembly and slide the clamp to secure the hose.
CONNECT OUTLET HEATER WATER HOSE
1. Connect the outlet heater water hose to the No. 3 water by-pass pipe and slide the clamp to secure the hose.
CONNECT INLET HEATER WATER HOSE
1. Connect the inlet heater water hose to the cylinder head sub-assembly and slide the clamp to secure the hose.
CONNECT HOSES AND CONNECTORS
1. Connect the vacuum pump hose to the vacuum pump assembly and slide the clip to secure the hose.
2. Install the injector driver assembly with the 2 nuts.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
3. for CCo:
  
  Connect the 4 injector driver connectors and attach the wire harness clamp.
4. for DPF:
  
  Connect the 4 injector driver connectors and attach the 2 wire harness clamps.
5. Attach the 3 wire harness clamps to the 3 wire harness clamp brackets.
6. for Automatic Transaxle:
  
  Connect the shift position switch connector and attach the 2 wire harness clamps.
7. for Automatic Transaxle:
  
  Install the ground cable with the bolt to the automatic transaxle.
  
  Torque:
  
  19 N*m { 194 kgf*cm, 14 ft.*lbf }
8. for Automatic Transaxle:
  
  Connect the transaxle ECM connector and attach the 2 wire harness clamps.
9. for Manual Transaxle:
  
  Install the bolt to the manual transaxle assembly.
  
  Torque:
  
  19 N*m { 194 kgf*cm, 14 ft.*lbf }
10. for Manual Transaxle:
  
  Connect the 2 connectors and attach the wire harness clamp.
11. for Manual Transaxle:
  
  Install the ground cable with the bolt and attach the wire harness clamp.
  
  Torque:
  
  19 N*m { 194 kgf*cm, 14 ft.*lbf }
12. Install the wire harness clamp bracket with the bolt.
  
  Torque:
  
  7.7 N*m { 79 kgf*cm, 68 in.*lbf }
13. Connect the starter wire with the nut.
  
  Torque:
  
  9.8 N*m { 100 kgf*cm, 87 in.*lbf }
14. Install the bolt and attach the engine wire cover clamp and engine wire harness clamp.
  
  Torque:
  
  7.7 N*m { 79 kgf*cm, 68 in.*lbf }
15. Attach the 2 claws and connect the engine wire to the engine room No. 1 relay block with the nut.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
16. Connect the 3 connectors to the engine room No. 1 relay block.
17. Install the engine room relay block and junction block cover.
INSTALL ECM

Click here
INSTALL AIR CLEANER BRACKET
1. Install the air cleaner bracket with the 3 bolts.
  
  Torque:
  
  7.5 N*m { 76 kgf*cm, 66 in.*lbf }
2. Connect the 2 fuel hoses to the air cleaner bracket.
3. Attach the 3 wire harness clamps.
4. Connect the glow plug relay and level warning switch connector.
INSTALL FUEL FILTER ASSEMBLY
1. Install the fuel filter assembly to the air cleaner bracket with the bolt.
  
  Torque:
  
  7.0 N*m { 71 kgf*cm, 62 in.*lbf }
2. Connect the 2 fuel hoses to the fuel filter assembly and slide the clamp secure the hoses.
INSTALL AIR CLEANER SUPPORT
1. Install the air cleaner support with the 2 nuts.
  
  Torque:
  
  7.0 N*m { 71 kgf*cm, 62 in.*lbf }
INSTALL AIR CLEANER CASE
1. Install the air cleaner case with the 3 bolts.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
INSTALL AIR CLEANER CAP SUB-ASSEMBLY
1. Install the air cleaner cap sub-assembly and attach the 3 clips.
2. Connect the mass air flow meter connector and wire harness clamp.
3. Connect the air cleaner hose and tighten the hose clamp.
4. Connect the PCV hose.
INSTALL NO. 3 AIR HOSE

Click here
CONNECT NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY

Click here
INSTALL RADIATOR ASSEMBLY (for Automatic Transaxle)

Click here
INSTALL BATTERY BRACKET REINFORCEMENT
1. Install the battery bracket reinforcement with the 2 bolts.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
INSTALL FRONT BATTERY BRACKET
1. Install the front battery bracket with the 4 bolts.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
2. Attach the 2 wire harness clamps.
INSTALL BATTERY TRAY
INSTALL BATTERY
INSTALL BATTERY INSULATOR
INSTALL BATTERY CLAMP SUB-ASSEMBLY
1. Attach the hook of the battery clamp sub-assembly to the front battery bracket.
2. Partially tighten the nut and temporarily install the bolt.
3. Attach the 2 wire harness clamps.
4. Adjust the battery clamp position.
5. Tighten the nut and bolt.
  
  Torque:
  
  for bolt
  
  17 N*m { 173 kgf*cm, 13 ft.*lbf }
  
  for nut
  
  4.9 N*m { 50 kgf*cm, 43 in.*lbf }
INSTALL DIFFERENTIAL PRESSURE SENSOR ASSEMBLY

Click here
INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

Click here
INSTALL FRONT EXHAUST PIPE ASSEMBLY

Click here
INSTALL FRONT BUMPER COVER (for Automatic Transaxle)

Click here
ADD MANUAL TRANSAXLE OIL (for Manual Transaxle)

Click here
ADD ENGINE OIL

Click here
CONNECT CABLE TO POSITIVE BATTERY TERMINAL
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Note

When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

Click here
BLEED AIR FROM FUEL SYSTEM

Click here
ADD AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle)

Click here
ADD ENGINE COOLANT

Click here
CHARGE REFRIGERANT

Click here
WARM UP ENGINE

Click here
INSPECT FOR REFRIGERANT LEAK

Click here
PERFORM REGISTRATION (for CCo)
1. Perform registration of the injector compensation codes.
  
  Click here
2. Perform registration of the pilot quantity learning.
  
  Click here
PERFORM REGISTRATION (for DPF)
1. Perform registration of the injector compensation codes.
  
  Click here
2. Perform registration of the pilot quantity learning.
  
  Click here
PERFORM INITIALIZATION
- for CCo:
  
  Click here
- for DPF:
  
  Click here
PERFORM THROTTLE VALVE FULLY CLOSED POSITION LEARNING

Click here
INSPECT FOR OIL LEAK

Click here
INSPECT FOR COOLANT LEAK

Click here
INSPECT FOR FUEL LEAK

Click here
INSPECT FOR EXHAUST GAS LEAK

Click here
INSPECT FOR MANUAL TRANSAXLE OIL LEAK (for Manual Transaxle)

Click here
ADJUSTMENT AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle)

Click here
INSTALL REAR ENGINE UNDER COVER RH

Click here
INSTALL ENGINE UNDER COVER REAR LH
1. Install the rear engine under cover LH with the 2 clips.
INSTALL FRONT FLOOR COVER RH
1. Install the front floor cover RH with the 3 nuts and 3 clips.
INSTALL NO. 2 ENGINE UNDER COVER
1. Install the No. 2 engine under cover with the bolt and clip.
  
  Torque:
  
  5.5 N*m { 56 kgf*cm, 49 in.*lbf }
INSTALL FRONT FLOOR COVER

Click here
INSTALL NO. 1 ENGINE UNDER COVER
1. Install the No. 1 engine under cover with the 10 clips.
2. Install the 4 bolts and 2 screws.
INSTALL NO. 1 ENGINE COVER
1. Attach the 4 clips to install the No. 1 engine cover.
CHECK IDLE SPEED

Click here
CHECK MAXIMUM ENGINE SPEED

Click here
ADJUST FRONT WHEEL ALIGNMENT

Click here
CHECK ABS SPEED SENSOR SIGNAL

Click here

*1	Alignment Mark
*2	Protrusion